Toyota CH-R Service Manual: Removal

REMOVAL

CAUTION / NOTICE / HINT

The necessary procedures (adjustment, calibration, initialization or registration) that must be performed after parts are removed and installed, or replaced during the front door window frame moulding removal/installation are shown below.

PROCEDURE

1. PRECAUTION

CAUTION:

Be sure to read Precaution thoroughly before servicing.

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NOTICE:

After turning the ignition switch off, waiting time may be required before disconnecting the cable from the negative (-) battery terminal. Therefore, make sure to read the disconnecting the cable from the negative (-) battery terminal notices before proceeding with work.

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2. REMOVE FRONT DOOR BELT MOULDING ASSEMBLY

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3. REMOVE FRONT DOOR OUTSIDE MOULDING SUB-ASSEMBLY

HINT:

When removing the front door outside moulding sub-assembly, heat the vehicle body and front door outside moulding sub-assembly using a heat light.

NOTICE:

Do not heat the vehicle body or moulding excessively.

(a) Using a heat light, heat the front door outside moulding sub-assembly.

(b) Apply protective tape around the front door outside moulding sub-assembly as shown in the illustration.

*a	Double-sided Tape
	Remove in this Direction (1)
	Remove in this Direction (2)
	Protective Tape

(c) Using a moulding remover D, disengage the clip and guide, and separate the double-sided tape and caulking sponge to remove the front door outside moulding sub-assembly as shown in the illustration.

4. DISCONNECT FRONT DOOR WEATHERSTRIP

(a) Using a clip remover, disengage the clips to disconnect the front door weatherstrip.

5. REMOVE DOOR FRAME UPPER GARNISH

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6. REMOVE FRONT DOOR GLASS RUN

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7. REMOVE FRONT DOOR FRONT LOWER FRAME SUB-ASSEMBLY

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8. REMOVE FRONT DOOR FIX WINDOW GLASS

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9. REMOVE FRONT DOOR UPPER WINDOW FRAME MOULDING

(a) Insert a 4.0 mm (0.157 in.) drill bit into a drill.

(b) Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration. Standard Measurement: Area Measurement A 5.0 mm (0.197 in.) NOTICE: Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

*a Tape

(c) Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the 6 rivets.

CAUTION:

Be careful of the drilled rivets, as they may be hot.

(d) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.

(e) Disengage the guide to remove the front door upper window frame moulding from the door frame.

10. REMOVE FRONT DOOR SCUFF PLATE

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11. REMOVE COWL SIDE TRIM BOARD

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12. REMOVE FRONT DOOR FRONT WINDOW FRAME MOULDING

(a) Disconnect each connector.

(b) Disengage each clamp.

(c) Remove the 5 bolts and front door panel sub-assembly. NOTICE: To prevent damage, when removing the front door panel sub-assembly, make sure that there are enough people available to hold it securely.

(d) Insert a 4.0 mm (0.157 in.) drill bit into a drill.

(e) Tape the 4.0 mm (0.157 in.) drill bit 5.0 mm (0.197 in.) from the tip as shown in the illustration. Standard Measurement: Area Measurement A 5.0 mm (0.197 in.) NOTICE: Tape the 4.0 mm (0.157 in.) drill bit to prevent the drill bit from going too deep.

*a Tape

(f) Lightly press the drill bit against the rivets to drill off the rivet flanges, and remove the 2 rivets and front door front window frame moulding.

CAUTION:

Be careful of the drilled rivets, as they may be hot.

(g) Using a vacuum cleaner, remove the rivet fragments and shavings from the drilled areas.